Centerset faucet body and method of making same

ABSTRACT

A molded waterway assembly for a centerset faucet including a hot water inlet tube, a cold water inlet tube, and a central body of a coupler overmolded within hot and cold water bodies of the coupler.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.13/087,586, filed Apr. 15, 2011, which claims priority from U.S.Provisional Patent Application Ser. No. 61/451,944, filed Mar. 11, 2011,the disclosures of which are hereby expressly incorporated by referenceherein.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to plumbing fixtures and, moreparticularly, to a faucet including a molded waterway assembly and to amethod of making the same.

Faucets are generally controlled by either a single handle whichutilizes a mixing valve to proportion the flow of hot water and coldwater to a delivery spout, or dual handles which utilize two separatevalves to independently control the flow of hot water and cold water. Ina conventional dual handle faucet, the hot water and cold water valvebodies, which house the respective hot water and cold water valves, areeach typically connected to an upstream waterway through a conventionalmechanical connection, such as mating threads. Further, each valve bodyis typically connected to a separate downstream waterway. In certainexamples, the valve bodies and the downstream waterways are sand castfrom brass, or are machined from brass components and combined throughbrazing. Sand casting is typically a manual low-tech process that if notcontrolled properly may lead to failures through pin holes or porosity.One of the potential problems with a brazing connection is thatundesirable materials, such as harmful metals, may be communicated fromthe brazing material into the water passageway through the brazedconnection. Further, brazing is often a variable process that may leadto failures. Additionally, brazing often requires an etching operationto be performed subsequent thereto.

According to an illustrative embodiment of the present disclosure, amethod is provided for forming a waterway for use with a centersetfaucet, the faucet including a first water supply, a second watersupply, a first valve, a second valve, and an outlet tube. The methodcomprising the steps of: molding a central body of a coupler having anoutlet channel that is configured for fluid communication with theoutlet tube; providing a first flexible tube including opposing proximaland distal ends, the first flexible tube configured for fluidcommunication with the first water supply; providing a second flexibletube including opposing proximal and distal ends, the second flexibletube configured for fluid communication with the second water supply;overmolding a first body of the coupler around the central body of thecoupler and around the first flexible tube, the first body of thecoupler defining at least a portion of a first valve interface forcommunicating with the first valve; and overmolding a second body of thecoupler around the central body of the coupler and around the secondflexible tube, the second body of the coupler defining at least aportion of a second valve interface for communicating with the secondvalve, the second valve interface being in spaced relation to the firstvalve interface.

According to another illustrative embodiment of the present disclosure,a method is provided for forming a waterway for use with a centersetfaucet, the faucet including a first water supply, a second watersupply, a first valve, a second valve, and an outlet tube. The methodincludes the steps of: molding a central body of a coupler, the centralbody of the coupler defining a first intermediate channel, a secondintermediate channel, and an outlet channel, the first intermediatechannel configured to direct fluid from the first valve to the outletchannel, the second intermediate channel configured to direct fluid fromthe second valve to the outlet channel, and the outlet channelconfigured to direct fluid to the outlet tube; providing a firstflexible tube including opposing proximal and distal ends, the firstflexible tube configured for fluid communication with the first watersupply; providing a second flexible tube including opposing proximal anddistal ends, the second flexible tube configured for fluid communicationwith the second water supply; overmolding a first body of the coupleraround the central body of the coupler and around the first flexibletube, the first body of the coupler defining a first inlet channelconfigured to direct fluid from the first flexible tube to the firstvalve; and overmolding a second body of the coupler around the centralbody of the coupler and around the second flexible tube, the second bodyof the coupler defining a second inlet channel configured to directfluid from the second flexible tube to the second valve.

According to yet another illustrative embodiment of the presentdisclosure, a waterway assembly is provided for use with a centersetfaucet, the faucet including a hot water valve, a cold water valve, andan outlet tube. The waterway assembly includes a hot water inlet tubeincluding opposing proximal and distal ends, a cold water inlet tubeincluding opposing proximal and distal ends, and a coupler including acentral body that defines a hot water intermediate channel, a cold waterintermediate channel, and an outlet channel, the hot water intermediatechannel configured to direct fluid from the hot water valve to theoutlet channel, the cold water intermediate channel configured to directfluid from the cold water valve to the outlet channel, and the outletchannel configured to direct fluid from the hot and cold waterintermediate channels to the outlet tube, a hot water body overmoldedonto the central body and the proximal end of the hot water inlet tube,the hot water body defining a hot water inlet channel configured todirect fluid from the hot water inlet tube to the hot water valve, and acold water body overmolded onto the central body and the proximal end ofthe cold water inlet tube, the cold water body defining a cold waterinlet channel configured to direct fluid from the cold water inlet tubeto the cold water valve.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1 is a perspective view of an illustrative faucet of the presentdisclosure mounted to a sink deck and fluidly coupled to hot and coldwater supply lines;

FIG. 2 is an exploded perspective view of a portion of the illustrativefaucet of FIG. 1, the faucet including an illustrative molded waterwayincluding a hot water body, a cold water body, a central body, and hotand cold inlet tubes;

FIG. 3 is a top plan view of the molded waterway of FIG. 2, the moldedwaterway shown without the hot and cold inlet tubes;

FIG. 4 is a bottom plan view of the molded waterway of FIG. 3;

FIG. 5 is a cross-sectional view of the molded waterway of FIG. 3, takenalong line 5-5 of FIG. 3;

FIG. 6 is a flow chart of an illustrative method of forming the moldedwaterway of FIG. 2;

FIG. 7 is a partial rear perspective view of the central body of themolded waterway during a first molding step;

FIG. 8 is a cross-sectional view of the central body of FIG. 7, takenalong line 8-8 of FIG. 7;

FIG. 9 is a cross-sectional view of the central body of FIG. 8, takenalong line 9-9 of FIG. 8;

FIG. 10 is a rear perspective view of the central body following thefirst molding step of FIG. 7;

FIG. 11 is cross-sectional view of the central body of FIG. 10, takenalong line 11-11 of FIG. 10;

FIG. 12 is a partial rear perspective view of the central body of themolded waterway before a second molding step;

FIG. 13 is a partial rear perspective view of the molded waterway duringa second molding step; and

FIG. 14 is cross-sectional view of the molded waterway of FIG. 13, takenalong line 14-14 of FIG. 13.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to precise forms disclosed. Rather,the embodiments selected for description have been chosen to enable oneskilled in the art to practice the invention.

Referring initially to FIGS. 1 and 2, an illustrative embodiment faucet10 is shown mounted atop sink deck 14. The illustrative faucet 10includes base 12 and escutcheon 13, which may be attached to sink deck14 with plastic shanks, threaded bolts, or other suitable fasteners (notshown).

Faucet 10 is fluidly coupled to hot water supply 16 and cold watersupply 18 through conventional stops (not shown). Hot and cold waterfluid transport components are provided in the form of inlet tubes 20and 22. Hot water inlet tube 20 includes proximal end 20 a and anopposing distal end 20 b. Similarly, cold water inlet tube 22 includesproximal end 22 a and an opposing distal end 22 b. Illustratively, inlettubes 20 and 22 are flexible such that the distal ends 20 b and 22 b maybe manipulated relative to the respective proximal ends 20 a and 22 a.For example, inlet tubes 20 and 22 may be formed of a polymer, such asan olefin or a polyethylene. In one illustrative embodiment, inlet tubes20 and 22 are formed of a polyethylene which has been cross-linked toform cross-linked polyethylene (PEX). However, it should be appreciatedthat other suitable materials may be substituted therefor.

While the illustrative inlet tubes 20 and 22 define a circularcross-section, it should be noted that the cross-sectional shape ofinlet tubes 20 and 22 may vary. For example, to facilitate subsequentmolding operations, the cross-section of proximal ends 20 a and 22 a ofinlet tubes 20 and 22 may be oval-shaped or D-shaped.

As shown in FIG. 1, fluid coupling 24 is provided at distal end 20 b ofhot water inlet tube 20 for connecting with hot water supply 16, andfluid coupling 26 is provided at distal end 22 b of cold water inlettube 22 for connecting with cold water supply 18. It should beappreciated that inlet tubes 20 and 22 may be directly coupled to therespective hot and cold water stops through corresponding fluidcouplings 24 and 26 or, alternatively, to intermediate hot and coldwater risers (not shown).

The illustrative faucet 10 also includes a centrally-disposed deliveryspout 40 that is supported above escutcheon 13, as shown in FIG. 1.Delivery spout 40 receives outlet tube 42 for delivering a mixed waterstream to a sink basin or a tub basin (not shown), for example. As shownin FIG. 2, faucet 10 may include sealing ring 44 to provide a sealbeneath collar 46 of outlet tube 42. Sealing ring 44 may be in the formof an elastomeric O-ring, for example.

Between inlet tubes 20 and 22 and outlet tube 42, the illustrativefaucet 10 further includes hot water valve 30 and cold water valve 32.Hot water valve 30 is fluidly coupled to hot water inlet tube 20 todeliver hot water to outlet tube 42, and cold water valve 32 is fluidlycoupled to cold water inlet tube 22 to deliver cold water to outlet tube42.

Hot water valve 30 includes valve member 31 that is movable between afirst “on” position where hot water from hot water inlet tube 20 is influid communication with outlet tube 42, and a second “off” positionwhere hot water from hot water inlet tube 20 is not in fluidcommunication with outlet tube 42. Valve member 31 may also be movableto a plurality of intermediate positions between the first “on” positionand the second “off” position to at least partially restrict the flow ofhot water from hot water inlet tube 20 to outlet tube 42. In oneillustrative embodiment, valve member 31 of hot water valve 30 is arotatable disc that may be rotatably adjusted through a hot water userinput, such as handle 34. As shown in FIG. 1, handle 34 generallyextends above escutcheon 13 of faucet 10 and is rotatable in thedirection of arrow 35. It should be appreciated that handle 34 may bereplaced with another type of user input, such as a lever.

Similarly, cold water valve 32 includes a valve member 33 that ismovable between a first “on” position where cold water from cold waterinlet tube 22 is in fluid communication with outlet tube 42, and asecond “off” position where cold water from cold water inlet tube 22 isnot in fluid communication with outlet tube 42. Valve member 33 may alsobe movable to a plurality of intermediate positions between the first“on” position and the second “off” position to at least partiallyrestrict the flow of cold water from cold water inlet tube 22 to outlettube 42. In one illustrative embodiment, valve member 33 of cold watervalve 32 is a rotatable disc that may be rotatably adjusted through acold water user input, such as handle 36. As shown in FIG. 1, handle 36generally extends above escutcheon 13 of faucet 10 and is rotatable inthe direction of arrow 37. As with handle 34 of hot water valve 30,handle 36 of cold water valve 32 may be replaced with another type ofuser input, such as a lever.

In one illustrative embodiment, valves 30 and 32 of faucet 10 may be ofthe type disclosed in International Patent Publication No. WO2009/155529, entitled “Valve Assembly for a Two Handle Faucet.”Additional exemplary rotatable valves are disclosed in U.S. Pat. Nos.3,645,493; 4,453,567; 4,577,835; and 4,700,928.

With reference to FIGS. 2-5, coupler 100 is provided to convey waterthrough faucet 10. The illustrative coupler 100 includes hot water body102 on one side, cold water body 104 on the other side, and central body106 extending therebetween. As shown in FIG. 2, hot water body 102 andcold water body 104 may be positioned at least partially rearward ofcentral body 106 to provide adequate space for drain lift rod 15 offaucet 10 (FIG. 1) behind central body 106.

Referring to FIG. 5, hot water body 102 of coupler 100 defines hot waterinlet channel 110 and cold water body 104 of coupler 100 defines coldwater inlet channel 112. Between inlet channels 110 and 112, hot waterbody 102 and central body 106 of coupler 100 cooperate to define anL-shaped, intermediate hot water channel 114, and cold water body 104and central body 106 of coupler 100 cooperate to define an L-shapedintermediate cold water channel 116. The L-shaped intermediate hot waterchannel 114 includes a vertical portion 114 a and a horizontal portion114 b, and the L-shaped intermediate cold water channel 116 includes avertical portion 116 a and a horizontal portion 116 b. In the center ofcoupler 100, between intermediate channels 114 and 116, central body 106defines outlet channel 118.

In operation, hot water from hot water inlet tube 20 (shown in phantomin FIG. 5) flows upwardly through hot water inlet channel 110 of coupler100 along arrow H₁, and cold water from cold water inlet tube 22 (shownin phantom in FIG. 5) flows upwardly through cold water inlet channel112 of coupler 100 along arrow C₁. Next, the hot and cold water exitscoupler 100 and flows through valves 30 and 32 (shown in phantom in FIG.5) along arrows H₂ and C₂, respectively. Then, the hot and cold waterre-enters coupler 100 and flows through intermediate hot water channel114 and intermediate cold water channel 116 of coupler 100 along arrowsH₃ and C₃, respectively. Finally, the hot and cold water combines toform a mixed water stream that flows upwardly through outlet channel 118of coupler 100 along arrow O and into outlet tube 42 (shown in phantomin FIG. 5) for delivery to a sink basin or a tub basin (not shown), forexample.

To provide leak-resistant, fluid communication between coupler 100 andinlet tubes 20 and 22 (e.g., along arrows H₁ and C₁ of FIG. 5), coupler100 may be overmolded about inlet tubes 20 and 22. Specifically, hotwater body 102 of coupler 100 may be overmolded about proximal end 20 aof hot water inlet tube 20, and cold water body 104 of coupler 100 maybe overmolded about proximal end 22 a of cold water inlet tube 22. Anillustrative method for overmolding coupler 100 about inlet tubes 20 and22 is discussed further below.

To provide leak-resistant, fluid communication between coupler 100 andvalves 30 and 32 (e.g., along arrows H₂ and C₂ of FIG. 5), coupler 100may support and interface with valves 30 and 32. In the illustrativeembodiment of FIG. 5, hot water body 102 extends over central body 106of coupler 100 to define first valve interface 120 for receiving andsupporting hot water valve 30 and, on the other end of coupler 100, coldwater body 104 extends over central body 106 of coupler 100 to definesecond valve interface 122 for receiving and supporting cold water valve32. It is also within the scope of the present disclosure that hot waterbody 102 and central body 106 may cooperate to define first valveinterface 120 and that cold water body 104 and central body 106 maycooperate to define second valve interface 122.

Each valve interface 120 and 122 of the illustrative coupler 100includes an upwardly projecting inlet wall 124 that surrounds anddefines a portion of the corresponding inlet channel 110 and 112 and anupwardly projecting outlet wall 126 that surrounds and defines a portionof the corresponding intermediate channel 114 and 116. When assembled,inlet walls 124 of each valve interface 120 and 122 direct fluid intorespective inlets of valves 30 and 32, and outlet walls 126 of eachvalve interface 120 and 122 receive fluid from respective outlets ofvalves 30 and 32. In the illustrative embodiment of FIG. 2, inlet wall124 and outlet wall 126 of each valve interface 120 and 122 aresubstantially D-shaped to provide adequate support for and sealing withvalves 30 and 32. Between and around each inlet wall 124 and outlet wall126, each valve interface 120 and 122 may include a recess or trench 128for receiving a suitable gasket 129 (FIG. 5). Also, as shown in FIG. 2,each valve interface 120 and 122 may include one or more peripherallocating notches 130 for receiving corresponding locating tabs 132 onvalves 30 and 32, respectively, to facilitate orientation therebetween.

To provide leak-resistant, fluid communication between coupler 100 andoutlet tube 42 (e.g., along arrow O of FIG. 5), coupler 100 may supportand interface with outlet tube 42. For example, in the illustrativeembodiment of FIG. 5, outlet tube 42 is sized for fluid-tight receiptwithin outlet channel 118 of coupler 100. This coupling may be enhancedby the presence of counterbore 140 for receiving sealing ring 44, whichis described above with respect to FIG. 2, between collar 46 of outlettube 42 and coupler 100.

Returning to FIG. 2, base 12 may define recess 60 that is sized andshaped to receive and support coupler 100 in faucet 10. The underside ofcoupler 100 may include suitable locating notches 62 (FIG. 5) and base12 may include corresponding pegs (not shown) to properly locate coupler100 within recess 60 of base 12. Also, faucet 10 may include sealingrings 64 to provide a seal between coupler 100 and base 12. Each sealingring 64 may be in the form of an elastomeric O-ring, for example. Base12 may be configured to engage threaded bonnet nuts (not shown) fortightening valves 30 and 32 onto coupler 100.

Additional information regarding faucet 10 and coupler 100 may be foundin International Patent Publication No. WO 2009/126887, entitled “MoldedWaterway for a Two Handle Faucet,” the entire disclosure of which isexpressly incorporated by reference herein.

As further detailed herein, and as shown in FIG. 5, coupler 100 isconstructed of a flowable material which is molded in a two-step processto form hot water inlet channel 110, cold water inlet channel 112,intermediate hot water channel 114, intermediate cold water channel 116,and outlet channel 118. While any suitable material may be used to formcoupler 100, a polymer, including thermoplastics and thermosets, isutilized in the illustrative embodiment. Specifically, polyethylene isutilized in the illustrative embodiment to form coupler 100, and thepolyethylene is then subsequently cross-linked. It should be noted thatreinforcing members, such as glass fibers, may be provided within thepolyethylene of coupler 100.

The basic principles of overmolding plumbing connections on tubes areshown in U.S. Pat. Nos. 5,895,695; 6,082,780; 6,287,501; and 6,902,210.U.S. Pat. No. 7,766,043 and U.S. Application Publication No.2007/0044852 also disclose illustrative overmolding about water inlettubes.

With reference now to FIGS. 6-14, an illustrative method 200 is providedfor forming the waterway assembly 90 of the present disclosure. In FIGS.7-9 and 12-14, one side (i.e., the cold water side) of coupler 100 isillustrated, but it will be understood that similar steps may beperformed to construct the opposite side (i.e., the hot water side) ofcoupler 100.

In a first molding step 202 of the illustrative method 200, central body106 of coupler 100 is formed. Step 202 is performed using a suitablefirst mold 300 (shown in phantom in FIG. 7) to define the exterior shapeof central body 106 and core pins 250, 252, and 254 to define theinterior shape of central body 106. As shown in FIGS. 7 and 8, firstcore pin 250 may be oriented vertically in the mold 300 and second corepin 252 may be oriented horizontally in the mold 300 (i.e.,perpendicular to first core pin 250) to cooperatively define theL-shaped intermediate cold water channel 116 in central body 106. Morespecifically, first core pin 250 may be oriented vertically in the mold300 to define the vertical portion 116 a of intermediate cold waterchannel 116 and second core pin 252 may be oriented horizontally in themold 300 to define the horizontal portion 116 b of intermediate coldwater channel 116. On the opposite side of coupler 100, a similar firstcore pin 250 and second core pin 252 may be used to form intermediatehot water channel 114 in central body 106. As shown in FIGS. 7 and 8,third core pin 254 may extend vertically in the mold 300 (i.e., parallelto first core pin 250) to define outlet channel 118 in central body 106.Although referred to herein as the first, second, and third core pins250, 252, and 254, the core pins 250, 252, and 254 may be inserted intothe mold 300 in any order.

To prevent material from leaking into intermediate channels 114 and 116during the molding process, especially at the elbow or bend where eachvertical portion 114 a and 116 a meets its respective horizontal portion114 b and 116 b, each first core pin 250 may at least partially straddlethe corresponding second core pin 252, as shown in FIG. 9. Such leakagescould lead to obstructions or blockages within intermediate channels 114and 116.

During step 202, a flowable material, illustratively a polymer such aspolyethylene, is injected into inlet 301 of the first mold 300 andaround core pins 250, 252, and 254. Then, the material is allowed tocool. Finally, central body 106 is removed from the mold 300 and corepins 250, 252, and 254 are removed or withdrawn. Exterior openings 150will be visible in each side of central body 106 in the space onceoccupied by second core pins 252, as shown in FIGS. 10 and 11.

In a second molding step 204 of the illustrative method 200, hot waterbody 102 and cold water body 104 of coupler 100 are overmolded aroundthe previously formed central body 106 of coupler 100 and around inlettubes 20 and 22. In certain embodiments, bodies 102 and 104 of coupler100 may be formed substantially simultaneously. In other embodiments,bodies 102 and 104 of coupler 100 may be formed in series.

Step 204 is performed using one or more suitable second molds 302 (shownin phantom in FIG. 13) to define the exterior shape of bodies 102 and104 and core pins 256 and 258 to define the interior shape of bodies 102and 104. Core pins 256 and 258 may be distinct components or, as shownin FIG. 12-14, core pins 256 and 258 may be interconnected. Fourth corepin 256 may be oriented vertically in the mold 302 to receive proximalend 22 a of cold water inlet tube 22 and to define cold water inletchannel 112 in cold water body 104 of coupler 100. On the opposite sideof coupler 100, a similar fourth core pin 256 may be used to receiveproximal end 20 a of hot water inlet tube 20 and to define hot waterinlet channel 110 in hot water body 102 of coupler 100. Fifth core pin258 may also be oriented vertically in the mold 302 (i.e., parallel tofourth core pin 256) to define the remainder of the vertical portion 116a of intermediate cold water channel 116 that extends through cold waterbody 104 of coupler 100. Also, fifth core pin 258 may at least partiallyfill intermediate cold water channel 116 while leaving opening 150 incentral body 106 of coupler 100 exposed. On the opposite side of coupler100, a similar fifth core pin 258 may be used to define the remainder ofthe vertical portion 114 a of intermediate hot water channel 114 thatextends through hot water body 102 of coupler 100 and to at leastpartially fill intermediate hot water channel 114 while leaving opening150 in central body 106 of coupler 100 exposed. Although referred toherein as the fourth and fifth core pins 256 and 258, the core pins 256and 258 may be inserted into the mold 302 in any order.

During step 204, a flowable material, illustratively a polymer such aspolyethylene, is injected into inlet 303 of each second mold 302 andaround core pins 256 and 258. Then, the material is allowed to cool.Finally, coupler 100 is removed from the molds 302 and core pins 256 and258 are removed or withdrawn. The resulting molded waterway assembly 90is shown in FIGS. 2 and 5. Because openings 150 in central body 106 ofcoupler 100 were exposed to the flowable material in the molds 302,bodies 102 and 104 of coupler 100 now fill openings 150.

Optionally, in step 206 of method 200, the molded waterway assembly 90is cross-linked. For example, if the molded waterway assembly 90 isconstructed of polyethylene during the first and second molding steps202 and 204, the polyethylene of inlet tubes 20 and 22 and coupler 100(which have not been cross-linked or have been only partiallycross-linked) may be cross-linked during step 206 to form cross-linkedpolyethylene (PEX). While it is envisioned that any form of suitablecross-linking may be utilized to form the PEX of inlet tubes 20 and 22and coupler 100, in one illustrative embodiment the polyethylene iscross-linked by bombarding it with electromagnetic (gamma) or highenergy electron (beta) radiation.

In the illustrative embodiment, no subsequent machining operations arerequired to finish coupler 100. For example, no subsequent machiningoperations are required to prepare first valve interface 120 of coupler100 to receive hot water valve 30 or to prepare second valve interface122 of coupler 100 to receive cold water valve 32. Also, no subsequentmachining operations are required to prepare outlet channel 118 ofcoupler 100 to receive outlet tube 42.

The illustrative method 200 involves overmolding hot water body 102 andcold water body 104 of coupler 100 around a previously formed centralbody 106 of coupler 100 and around inlet tubes 20 and 22. While theprecise composition of inlet tubes 20 and 22 and coupler 100 are notrequired to be of any specified polymer, in general, there are severalguidelines which are applicable in the practice of the illustrativeembodiment. It is of course, recognized that the precise operatingconditions utilized in the overmolding process are well-known in the artand are specific to each molded polymer. It is well within the skill ofthe art to determine the applicable conditions which will result in theappropriate inlet tubes 20 and 22 and coupler 100. Inlet tubes 20 and 22and coupler 100 may be a thermoplastic or a thermoset. Illustratively,the polymer overmolded bodies 102 and 104 of coupler 100 should becapable of forming leak-proof bonds, either chemical or physical, withthe polymer of the underlying inlet tubes 20 and 22 and with the polymerof the underlying central body 106 of coupler 100.

Illustrative and non-limiting examples of the polymers which may be usedin various combinations to form the underlying inlet tubes 20 and 22 andcentral body 106 of coupler 100, as well as polymers which may be usedin the overmolding process to form bodies 102 and 104 of coupler 100,include: polyacetals, typically highly crystalline linear thermoplasticpolymers of oxymethylene units; poly(meth)acrylics, typically belongingto two families of esters, acrylates and methacrylates; polyaryletherketones containing ether and ketone groups combined with phenyl rings indifferent sequences and polyether ketones; polyacrylonitrile resinswherein the principal monomer is acrylonitrile; nylons or polyamides,including various types of nylon-6, nylon-6/6, nylon-6/9, nylon-6/10,nylon-6/12, nylon-11, nylon-12; polyamide-imides formed by thecondensation of trimellitic anhydride and various aromatic diamines;polyacrylates of aromatic polyesters derived from aromatic dicarboxylicacids and diphenols; polybutene resins based on poly(1-butene);polycarbonates, typically based on bisphenol A reacted with carbonylchloride; polyalkylene terephthalates typically formed in atransesterification reaction between a diol and dimethyl terephthalate;polyetherimides, based on repeating aromatic imide and ether units;polyethylene homopolymers and copolymers, including all molecular weightand density ranges and degrees of crosslinking; polypropylenehomopolymers and copolymers; ethylene acid copolymers from thecopolymerization of ethylene with acrylic or methacrylic acid or theircorresponding acrylate resins; ethylene-vinyl acetate copolymers fromthe copolymerization of ethylene and vinyl acetate; ethylene-vinylalcohol copolymers; polyimides derived from the aromatic diamines andaromatic dianhydrides; polyphenylene oxides including polystyrenemiscible blends; polyphenylene sulfides; acrylonitrile butadiene styreneterpolymers; polystyrenes; styrene-acrylonitrile copolymers;styrene-butadiene copolymers thermoplastic block copolymers; styrenemaleic anhydride copolymers; polyarylsulfones; polyethersulfones;polysulfones; thermoplastic elastomers covering a hardness range of from30 Shore A to 75 Shore D, including styrenic block copolymers,polyolefin blends (TPOS), elastomeric alloys, thermoplasticpolyurethanes (TPUS), thermoplastic copolyesters, and thermoplasticpolyamides; polyvinyl chlorides and chlorinated polyvinyl chlorides;polyvinylidene chlorides; allyl thermosets of allyl esters based onmonobasic and dibasic acids; bismaleimides based generally on thecondensation reaction of a diamine with maleic anhydride; epoxy resinscontaining the epoxy or oxirane group, including those epoxy resinsbased on bisphenol A and epichlorohydrin as well as those based on theepoxidation of multifunctional structures derived from phenols andformaldehyde or aromatic amines and aminophenols; phenolic resins;unsaturated thermoset polyesters including those of the condensationproduct of an unsaturated dibasic acid (typically maleic anhydride) anda glycol, wherein the degree of unsaturation is varied by including asaturated dibasic acid; thermoset polyimides; polyurethanes containing aplurality of carbamate linkages; and urea and melamine formaldehyderesins (typically formed by the controlled reaction of formaldehyde withvarious compounds that contain the amino group).

The combination of the above polymers illustratively satisfy at leasttwo simultaneous conditions. First, the underlying inlet tubes 20 and 22and central body 106 of coupler 100 illustratively do not soften andbegin melt flow to the point where they lose structural integrity. Thus,according to the illustrative embodiment, the underlying inlet tubes 20and 22 and central body 106 of coupler 100 are capable of maintainingstructural integrity during the overmolding conditions during which theovermolded polymer is in melt flow. Second, the overmolded bodies 102and 104 of coupler 100 are illustratively capable of forming anessentially leak-proof interface with the underlying plastic, preferablythrough either a chemical and/or physical bond between the overmoldedplastic and the underlying plastic.

While using polymer compositions which have differing softening pointsis one way to achieve the above objectives, there are alternatives, oneof which would include the use of two compositions which have the samesoftening point, but which are of different thickness. Throughmanipulation of the time, temperature, and pressure conditionsexperienced during the molding operation, the underlying inlet tubes 20and 22 and central body 106 of coupler 100 would not experience meltflow, even though they had a similar softening point or range. It isalso possible that, through the incorporation of various additives inthe polymeric compositions (e.g., glass fibers, heat stabilizers,anti-oxidants, plasticizers, etc.), the softening temperatures of thepolymers may be controlled.

In an illustrative embodiment of the invention, the composition of theovermolded bodies 102 and 104 of coupler 100 will be such that they willbe capable of at least some melt fusion with the composition of theunderlying inlet tubes 20 and 22 and central body 106 of coupler 100,thereby maximizing the leak-proof characteristics of the interfacebetween the underlying inlet tubes 20 and 22 and the overmolded bodies102 and 104 of coupler 100 and the interface between the underlyingcentral body 106 of coupler 100 and the overmolded bodies 102 and 104 ofcoupler 100. There are several means by which such melt fusion may beeffected. One of the simplest procedures is to ensure that at least acomponent of the underlying inlet tubes 20 and 22 and central body 106of coupler 100 is the same as that of the overmolded bodies 102 and 104of coupler 100. Alternatively, it would be possible to ensure that atleast a portion of the polymer composition of the underlying inlet tubes20 and 22 and central body 106 of coupler 100 is sufficiently similar orcompatible with that of the overmolded bodies 102 and 104 of coupler 100so as to permit the melt fusion or blending or alloying to occur atleast in interfacial regions. For example, the polymer composition ofthe underlying inlet tubes 20 and 22 and central body 106 of coupler 100and the polymer composition of the overmolded bodies 102 and 104 ofcoupler 100 may be miscible.

In another illustrative embodiment of the invention, composites ofrubber/thermoplastic blends are useful in adhering to thermoplasticmaterials used in inlet tubes 20 and 22. These blends are typically inthe form of a thermoplastic matrix containing rubber nodulesfunctionalized and vulcanized during the mixing with the thermoplastic.Composite bodies 102 and 104 of coupler 100 may be formed by overmoldingthe vulcanized rubber/thermoplastic blend onto the thermoplastic inlettubes 20 and 22. In this manner, the cohesion at the interface betweenthese two materials is generally higher than the tensile strength ofeach of the two materials.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

The invention claimed is:
 1. A method of forming a waterway for use witha centerset faucet, the faucet including a first water supply, a secondwater supply, a first valve, a second valve, and an outlet tube, themethod comprising the steps of: molding a continuous unitary centralbody of a coupler, the central body defining a first intermediatechannel, a second intermediate channel, and an outlet channel, the firstintermediate channel configured to direct fluid from the first valve tothe outlet channel, the second intermediate channel configured to directfluid from the second valve to the outlet channel, and the outletchannel configured to direct fluid to the outlet tube; selecting a firstflexible tube including opposing proximal and distal ends, the firstflexible tube configured for fluid communication with the first watersupply; selecting a second flexible tube including opposing proximal anddistal ends, the second flexible tube configured for fluid communicationwith the second water supply; and after the molding step, overmolding afirst body of the coupler around the central body of the coupler and thefirst flexible tube and a second body of the coupler around the centralbody of the coupler and the second flexible tube, the first body of thecoupler defining at least a portion of a first valve interface forcommunicating with the first valve and the second body of the couplerdefining at least a portion of a second valve interface forcommunicating with the second valve, the overmolding step comprisinginserting pins into the first and second intermediate channels of thecentral body of the coupler.
 2. The method of claim 1, wherein themolding step comprises injecting a flowable material into a mold, themethod further comprising the step of cooling the flowable materialbefore the overmolding step.
 3. The method of claim 2, wherein theflowable material is a polymer.
 4. The method of claim 3, wherein theflowable material is polyethylene.
 5. The method of claim 1, wherein thesecond valve interface is in spaced relation to the first valveinterface.
 6. The method of claim 1, further comprising the step ofwithdrawing pins from the central body of the coupler before theovermolding step to leave behind the first intermediate channel, thesecond intermediate channel, and the outlet channel.
 7. The method ofclaim 6, wherein the withdrawing step leaves behind exterior openings inthe central body of the coupler, the overmolding step further comprisingfilling the exterior openings in the central body of the coupler.
 8. Themethod of claim 1, further comprising the step of withdrawing pins fromthe first and second bodies of the coupler after the overmolding step toleave behind a first inlet channel in the first body of the coupler thatis configured to direct fluid from the first flexible tube to the firstvalve and a second inlet channel in the second body of the coupler thatis configured to direct fluid from the second flexible tube to thesecond valve.
 9. The method of claim 1, wherein the first intermediatechannel extends through both the central body and the first body of thecoupler and the second intermediate channel extends through both thecentral body and the second body of the coupler.
 10. The method of claim1, wherein the first body of the coupler is simultaneously overmoldedaround the central body of the coupler and the proximal end of the firstflexible tube.
 11. The method of claim 1, wherein the second body of thecoupler is simultaneously overmolded around the central body of thecoupler and the proximal end of the second flexible tube.
 12. The methodof claim 1, further comprising the step of cross-linking the waterway.13. A method of forming a waterway for use with a centerset faucet, thefaucet including a first water supply, a second water supply, a firstvalve, a second valve, and an outlet tube, the method comprising thesteps of: molding a continuous unitary central body of a coupler, thecentral body defining a first intermediate channel, a secondintermediate channel, and an outlet channel, the first intermediatechannel configured to direct fluid from the first valve to the outletchannel, the second intermediate channel configured to direct fluid fromthe second valve to the outlet channel, and the outlet channelconfigured to direct fluid to the outlet tube; selecting a firstflexible tube including opposing proximal and distal ends, the firstflexible tube configured for fluid communication with the first watersupply; selecting a second flexible tube including opposing proximal anddistal ends, the second flexible tube configured for fluid communicationwith the second water supply; and after the molding step, overmolding afirst body of the coupler around the central body of the coupler and thefirst flexible tube and a second body of the coupler around the centralbody of the coupler and the second flexible tube, the first body of thecoupler defining a first inlet channel configured to direct fluid fromthe first flexible tube to the first valve and the second body of thecoupler defining a second inlet channel configured to direct fluid fromthe second flexible tube to the second valve.
 14. The method of claim13, wherein a portion of the first intermediate channel is locatedwithin the first body of the coupler and a portion of the secondintermediate channel is located within the second body of the coupler.15. The method of claim 14, wherein the portion of the firstintermediate channel located within the first body of the coupler andthe portion of the second intermediate channel located within the secondbody of the coupler extend parallel to the outlet channel in the centralbody of the coupler.
 16. The method of claim 13, wherein the first inletchannel in the first body of the coupler and the second inlet channel inthe second body of the coupler extend parallel to the outlet channel inthe central body of the coupler.
 17. The method of claim 13, wherein thefirst and second bodies of the coupler are formed substantiallysimultaneously during the overmolding step.